Electrical connector mating port enclosed by inner sleeve and outer cover

ABSTRACT

An electrical connector includes: a connector unit having a mating part, the mating part defining a front mating end; a sleeve enclosing the mating part and extending forwardly beyond the front mating end to define a receiving chamber; and an outer cover enclosing the sleeve and the connector unit, wherein the sleeve has a front portion containing the receiving chamber, and the outer cover is made of a material softer than the sleeve.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to an electrical connector comprising: aconnector unit having a mating part, the mating part defining a frontmating end; a sleeve enclosing the mating part and extending forwardlybeyond the front mating end to define a receiving chamber; and an outercover enclosing the sleeve and the connector unit, wherein the sleeve isdesigned to provide desired structural strength while the outer cover isdesigned to be versatile in color, material, and finish.

2. Description of Related Art

U.S. Pat. No. 9,831,610 discloses a cable connector comprising: aconnector unit having a mating part, the mating part defining a frontmating end; and an insulative connector housing that is formed from twointer engaging halves that cooperatively define a hollow interior thathouses a connector body of the connector unit therein.

SUMMARY OF THE INVENTION

An electrical connector comprises: a connector unit having a matingpart, the mating part defining a front mating end; a sleeve enclosingthe mating part and extending forwardly beyond the front mating end todefine a receiving chamber; and an outer cover enclosing the sleeve andthe connector unit, wherein the sleeve has a front portion containingthe receiving chamber, and the outer cover is made of a material softerthan the sleeve.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of an electrical connector in accordancewith a first embodiment of the present invention;

FIG. 2 is an exploded view of the electrical connector omitting an outercover thereof;

FIG. 3 is a view similar to FIG. 2 but from a different perspective;

FIG. 4 is a further exploded view of the electrical connector in FIG. 2;

FIG. 5 is a view similar to FIG. 5 but from a different perspective;

FIG. 6 is a perspective view of a mating part of the electricalconnector;

FIG. 7 is an exploded view of the mating part;

FIG. 8 is a perspective view of a sleeve of the electrical connector;

FIG. 9 is another exploded view of the electrical connector in FIG. 1;

FIG. 10 is a further exploded view of the electrical connector in FIG.9;

FIG. 11 is a cross-sectional view of the electrical connector takenalong line A-A in FIG. 1;

FIG. 12 is a cross-sectional view of the electrical connector takenalong line B-B in FIG. 1;

FIG. 13 is a perspective view of a mating connector in accordance withthe present invention;

FIG. 14 is an exploded view of the mating connector;

FIG. 15 is a view similar to FIG. 14 but from a different perspective;

FIG. 16 is a further exploded view of the mating connector in FIG. 14;

FIG. 17 is a further exploded view of the mating connector in FIG. 15;

FIG. 18 is a perspective view of the electrical connector and the matingconnector prior to mating;

FIG. 19 is a perspective view of the electrical connector and the matingconnector in mating;

FIG. 20 is a cross-sectional view of the electrical connector and themating connector taken along line C-C in FIG. 18;

FIG. 21 is a cross-sectional view of the electrical connector and themating connector taken along line C-C in FIG. 19;

FIG. 22 is a perspective view of an electrical connector in accordancewith a second embodiment of the present invention;

FIG. 23 is an exploded view of the electrical connector in FIG. 22;

FIG. 24 is a further exploded view of the electrical connector in FIG.23;

FIG. 25 is a still further exploded view of the electrical connector inFIG. 24; and

FIG. 26 is a perspective view of a divider of the electrical connectorin FIG. 22.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1-12, an electrical connector 100 of a firstembodiment comprises a connector unit 101, a sleeve 200, and an outercover 30. The electrical connector 100 may further comprise an innermold/cover 20 to adapt to various designs of the sleeve 200.

The connector unit 101 includes a metallic shell 60, a contact module 70received in the shell 60, a printed circuit board (PCB) 80 connected toplural conductive contacts 78 of the module 70, and a cable 90 connectedto a rear of the PCB 80. The contact module 70 has a first part 71 and asecond part 72. One of the first part 71 and the second part 72 has atongue 75. Each contact 78 has a tail 781 for soldering to the PCB 80. Amating part 10 is defined at a front of the connector unit 101 where theshell 60 encloses the tongue 75 of the contact module 70. An annularmating space 113 is defined between the tongue 75 and the shell 60. Themating part 10 has a front mating end 11. The shell 60 has a pair ofopenings 65 near the end 11. The connector unit 101 may further includean outer shell 40 attached to a rear of the shell 60 and enclosing thePCB 80 and a front of the cable 90. The outer shell 40 includes an upperbody 41 and a lower body 42.

The sleeve 200 is formed separately and then mounted to the mating part10 of the electrical connector 100. The sleeve 200 has a front portion211 and a rear portion 221 that is mounted in a sealing manner to theshell 60. A cross-sectional interior dimension of the rear portion 221of the sleeve 200 is less than a cross-sectional interior dimension ofthe front portion 211 of the sleeve 200. The front portion 211 has anend face 210. The sleeve 200 has a front end face 241, a rear end face242, and a receiving space through the front and rear end faces. Thefront portion 211 and the rear portion 221 each have one or morerecesses 215. The front portion 211 extends forwardly beyond the frontmating end 11 of the mating part 10 to define a receiving chamber 230.The front portion 211 of the sleeve 200 has one or more reinforcing ribs231 in the receiving chamber 230. The rear portion 221 has a pair ofindentations 260 at positions corresponding to the pair of openings 65of the shell 60. Provision of the sleeve 200 at the mating part 10strengthens overall structure.

The inner mold 20 is molded over the rear portion 221 of the sleeve 200.The inner mold 20 spans from the end face 210 of the front portion 211and has an exterior dimension substantially equal to that of the frontportion 211 of the sleeve 200. The recesses 215 on the rear portion 221help bonding of the inner mold 20 due to protrusions (not shown) formedon the inner mold 20 and received within the corresponding recesses 215.The rear portion 221 also helps sealing the openings 65 during moldingthe inner mold 20.

The outer cover 30 is molded over the front portion 211 of the sleeve200 and the inner mold 20. The outer cover 30 is made of a materialsofter than the sleeve 200. Therefore, the design of the outer cover 30becomes versatile in terms of color, material, and finish.

Referring to FIGS. 13-17, a mating connector 300 comprises a connectorunit 310 and an outer cover 330. The connector unit 310 includes ametallic shell 360, a contact module received in the shell 360, aprinted circuit board (PCB) 380 connected to upper and lower rows ofcontacts 363 of the contact module, a cable 390 connected to a rear ofthe PCB 380, and a wire organizer 391. The connector unit 310 mayfurther include an outer shell 340 attached to a rear of the shell 360and enclosing the PCB 380 and a front of the cable 390. A mating part311 is defined at a front of the connector unit 310 where the shell 360encloses the contact module. A mating space 313 is defined in the shell360 between the upper row of contacts and the lower row of contacts forreceiving the tongue 75 of the electrical connector 100. The shell 360has a pair of latches 315 for cooperating with the pair of openings 65of the electrical connector 100.

The outer cover 330 has a first part 331 and a second part 333 in frontof the first part 331. An exterior dimension of the first part 331 isgreater than an exterior dimension of the second part 333. The secondpart 333 has one or more recesses 334 for cooperating with the one ormore ribs 231 in the receiving chamber 230 of the electrical connector100. The outer cover 330 encloses the connector unit 310; the matingpart 311 of the connector 300 extends forwardly beyond the second part333 of the outer cover 330.

Referring to FIGS. 18-21, a shape and dimension of the receiving chamber230 of the electrical connector 100 generally matches or is greater thana shape and dimension of the second part 333 of the mating connector300. A cross-sectional exterior dimension of the outer cover 30 of theelectrical connector 100 is generally equal to a cross-sectionalexterior dimension of the first part 331 of the mating connector 300.

Referring to FIGS. 22-26, an electrical connector 500 of a secondembodiment comprises a connector unit 101 of generally same structure asin the first embodiment, a sleeve 52, and an outer cover 53 of generallysame structure as the outer cover 30 in the first embodiment. Theelectrical connector 500 may further comprise a divider 50 for sealingthe metallic shell 60 during molding the sleeve 52. In one non-limitingsense, the sleeve 52 in the second embodiment replaces the combinationof the sleeve 200 and the inner mold 20 in the first embodiment. Inanother also non-limiting sense, the divider 50 in the second embodimentsubstitutes for the rear portion 221 of the sleeve 200 in the firstembodiment.

The sleeve 52 is molded over the connector unit 101, and the divider 50if present, and extends forwardly beyond the front mating end 11 of themating part 10 to define a receiving chamber 530. The sleeve 52 has oneor more reinforcing ribs 531 in the receiving chamber 530 forcooperating with the one or more recesses 334 of the mating connector300. A shape and dimension of the receiving chamber 530 of theelectrical connector 500 generally matches or is greater than a shapeand dimension of the second part 333 of the mating connector 300.Provision of the sleeve 52 at the mating part 10 strengthens overallstructure.

The divider 50 is formed separately and then mounted to the mating part10 of the electrical connector 100. Therefore, the divider 50 seals themetallic shell 60 of the mating part 10 and then the sleeve 52 isintegrally molded over the divider 50 and the connector unit 10. Thedivider 50 has one or more recesses 550 to help bonding of the sleeve 52to the divider 50. The divider 50 has a pair of indentations 560 atpositions corresponding to the pair of openings 65 of the shell 60 foraccommodating the pair of latches 315 on the mating part 311 of themating connector 300.

The outer cover 53 is molded over the sleeve 52. The outer cover 53 ismade of a material softer than the sleeve 52. Therefore, the design ofthe outer cover 53 is versatile in terms of color, material, and finish.

Both the connector 100 of the first embodiment and the connector 500 ofthe second embodiment have respective reinforcing ribs 231 and 531exposed to the receiving chambers 230 and 530 of the sleeves 200 and 52for engaging the recesses 334 of the mating connector 300 in order tostrengthen their mating connection. In both embodiments, the pair oflatches 315 on the mating part 311 of the mating connector 300 are alsoprovided for latching into the pair of openings 65 on the shell 60 ofthe mating part 10.

In brief, both the embodiments disclose an insulative rear tubular part,i.e., the rear portion 221 of the sleeve 200 or the divider 50, toenclose the mating part of the connector unit, and such an insulativerear tubular part is enclosed within an insulative cover over-moldedthereon wherein another insulative front tubular part is located infront of the aforementioned insulative rear tubular part to form areceiving chamber which is aligned with the mating part of the connectorunit in the front-to-back direction and is radially larger than theinsulative rear tubular part, and such another insulative front tubularpart is unitarily formed either with the insulative rear tubular part asdisclosed in the first embodiment or with the inner cover as disclosedin the second embodiment.

What is claimed is:
 1. An electrical connector comprising: a connectorunit having a mating part, the mating part defining a front mating end;a sleeve enclosing the mating part and extending forwardly beyond thefront mating end to define a receiving chamber; and an outer coverenclosing the sleeve and the connector unit; wherein the sleeve has afront portion containing the receiving chamber; the outer cover is madeof a material softer than the sleeve; the mating part of the connectorunit has a metallic shell, and the sleeve has a rear portion sealing themetallic shell; and the metallic shell has a pair of latching openings.2. The electrical connector as claimed in claim 1, further comprising adivider, and wherein the mating part of the connector unit has ametallic shell sealed by the divider, and the sleeve is integrallymolded over the divider and the connector unit.
 3. The electricalconnector as claimed in claim 2, wherein the front portion of the sleevehas a reinforcing rib in the receiving chamber.
 4. An electricalconnector comprising: a connector unit having a mating part, the matingpart defining a front mating end; a sleeve enclosing the mating part andextending forwardly beyond the front mating end to define a receivingchamber; and an outer cover enclosing the sleeve and the connector unit;wherein the sleeve has a front portion containing the receiving chamber;and the outer cover is made of a material softer than the sleevez themating part of the connector unit has a metallic shell, and the sleevehas a rear portion sealing the metallic shell; and a cross-sectionalinterior dimension of the rear portion of the sleeve is less than across-sectional interior dimension of the front portion of the sleeve.5. The electrical connector as claimed in claim 4, further comprising aninner mold molded over the rear portion of the sleeve and having anexterior dimension substantially equal to that of the front portion ofthe sleeve.
 6. The electrical connector as claimed in claim 4, whereinthe metallic shell has a pair of latching openings.
 7. The electricalconnector as claimed in claim 4, further comprising a divider, andwherein the mating part of the connector unit has a metallic shellsealed by the divider, and the sleeve is integrally molded over thedivider and the connector unit.
 8. The electrical connector as claimedin claim 4, wherein the front portion of the sleeve has a reinforcingrib in the receiving chamber.
 9. The electrical connector as claimed inclaim 4, wherein a front end face of the sleeve and a front end face ofthe outer cover are substantially flush.
 10. An electrical sableconnector for mating with another cable a mating connector, comprising:a connector unit having a mating part in a front section thereof, themating part defining a front mating end; an insulative sleeve enclosingthe mating part and extending forwardly beyond the front mating end todefine a receiving chamber; and an insulative outer cover enclosing thesleeve and the connector unit; wherein the sleeve has a front portioncontaining the receiving chamber; wherein the mating part includes ametallic shell enclosing a tongue of a contact module therein with anannular mating space therebetween radially; and the shell forms a pairof openings communicating with the mating space for engagement with apair of latches of the mating connector.
 11. The electrical connector asclaimed in claim 10, wherein the sleeve forms at least one rib extendinginto the receiving chamber for engagement with an insulative outer coverof the mating connector.
 12. The electrical connector as claimed inclaim 10, wherein the sleeve forms a pair of indentationscommunicatively aligned with the corresponding pair of openings in avertical direction for receiving the pair of latches of the matingconnector.
 13. The electrical connector as claimed in claim 10, furtherincluding an insulative inner mold enclosing a rear part of the sleevewhile being coplanar with a front part of the sleeve.
 14. The electricalconnector as claimed in claim 13, wherein the outer cover enclosing boththe sleeve and the inner mold.
 15. An electrical connector for matingwith another cable connector, comprising: a connector unit having amating part in a front section thereof, the mating part defining a frontmating end and including a metallic shell enclosing a tongue of acontact module therein with an annular mating space therebetweenradially, the shell forming a pair of openings communicating with themating space in a vertical direction for receiving a pair of latches ofthe another cable connector; an insulative rear tubular part enclosingthe mating part to cover the pair of opening in the vertical direction;an insulative front tubular part located in front of the insulative reartubular part along a front-to-back direction perpendicular to thevertical direction, and radially larger than the insulative rear tubularpart to form a receiving chamber therein; and an insulative coverover-molded upon the insulative rear tubular part circumferentially;wherein the insulative front tubular part is unitarily formed eitherwith the insulative rear tubular part or with the insulative cover. 16.The electrical connector as claimed in claim 15, wherein the insulativerear tubular part forms a plurality recess in an exterior face facing toreceive corresponding protrusions of the insulative cover.
 17. Theelectrical connector as claimed in claim 15, wherein the insulative reartubular part forms a pair of indentations communicatively aligned withthe corresponding pair of openings for receiving the pair of latches ofsaid another cable connector.
 18. The electrical connector as claimed inclaim 17, wherein the insulative front tubular part forms at least onerib inwardly extending toward the receiving chamber for engagement withsaid another cable connector.
 19. The electrical connector as claimed inclaim 15, further including another insulative outer cover to encloseboth the insulative rear tubular part and the insulative front tubularpart circumferentially when the insulative front tubular part isunitarily formed with the insulative rear tubular part.
 20. Theelectrical connector as claimed in claim 19, wherein said insulativecover is essentially coplanar with the insulative front tubular partalong the front-to-back direction.